Tribological Mechanism of Graphene and Ionic Liquid Mixed Fluid on Grinding Interface under Nanofluid Minimum Quantity Lubrication

Graphene has superhigh thermal conductivity up to 5000 W/(m·K),extremely thin thickness,superhigh mechanical strength and nano-lamellar structure with low interlayer shear strength,making it possess great potential in mini-mum quantity lubrication(MQL)grinding.Meanwhile,ionic liquids(ILs)have higher thermal conductivity and better thermal stability than vegetable oils,which are frequently used as MQL grinding fluids.And ILs have extremely low vapor pressure,thereby avoiding film boiling in grinding.These excellent properties make ILs also have immense potential in MQL grinding.However,the grinding performance of graphene and ionic liquid mixed fluid under nano-fluid minimum quantity lubrication(NMQL),and its tribological mechanism on abrasive grain/workpiece grinding interface,are still unclear.This research firstly evaluates the grinding performance of graphene and ionic liquid mixed nanofluids(graphene/IL nanofluids)under NMQL experimentally.The evaluation shows that graphene/IL nanofluids can further strengthen both the cooling and lubricating performances compared with MQL grinding using ILs only.The specific grinding energy and grinding force ratio can be reduced by over 40%at grinding depth of 10μm.Work-piece machined surface roughness can be decreased by over 10%,and grinding temperature can be lowered over 50℃at grinding depth of 30μm.Aiming at the unclear tribological mechanism of graphene/IL nanofluids,molecular dynamics simulations for abrasive grain/workpiece grinding interface are performed to explore the formation mechanism of physical adsorption film.The simulations show that the grinding interface is in a boundary lubrication state.IL molecules absorb in groove-like fractures on grain wear flat face to form boundary lubrication film,and graphene nanosheets can enter into the grinding interface to further decrease the contact area between abrasive grain and workpiece.Compared with MQL grinding,the average tangential grinding force of graphene/IL nanofluids can decrease up to 10.8%.The interlayer shear effect and low interlayer shear strength of graphene nanosheets are the principal causes of enhanced lubricating performance on the grinding interface.EDS and XPS analyses are further carried out to explore the formation mechanism of chemical reaction film.The analyses show that IL base fluid happens chemical reactions with workpiece material,producing FeF_(2),CrF_(3),and BN.The fresh machined surface of workpiece is oxidized by air,producing NiO,Cr_(2)O_(3) and Fe_(2)O_(3).The chemical reaction film is constituted by fluorides,nitrides and oxides together.The combined action of physical adsorption film and chemical reaction film make graphene/IL nano-fluids obtain excellent grinding performance.

Phase Transformation Mechanism of Graphite-Turbostratic Graphite in the Course of Mechanical Grinding

The transformation from graphite to turbostratic graphite by means of the treatment with high energy ball milling was investigated by X ray powder diffraction method. It is believed that the size effect of nano crystal leads to this transformation. A possible transformation mechanism is proposed from the change of the eletronic structure of the hexagonal plane of the carbon atoms.

Study of the material removal mechanism of glass-ceramics based on consecutive incremental loading in ductile-regime grinding

Glass-ceramics have many excellent properties and are widely used in various fields. During the grinding process,the workpiece surface is typically subject to material removal by grit of incremental heights, which has rarely been the focus of research. As such, it is necessary to study the material removal mechanism of glass-ceramics under consecutive incremental loading, which more closely reflects the actual grinding process. In this paper,to analyze the plastic deformation and residual stress of lithium aluminosilicate(LAS) glass-ceramics, a finite element model is established based on the Drucker–Prager yield criterion for ductile regimes. A nano-scratch test was also conducted and the test results show that both the residual depth and residual stress increase with an increase in the number of increments, and that consecutive incremental loading promotes the plastic deformation of glass-ceramics and increases the residual stress of the material in the ductile-regime process. These findings provide guidance for achieving higher dimensional accuracy in the actual grinding of glass-ceramics parts.

Fragmentation mechanism of low-grade hematite ore in a high pressure grinding roll

The fragmentation mechanism of low-grade hematite ore in a high pressure grinding roll(HPGR) was studied based on the characteristics of comminuted products at different specific pressure levels. The major properties included the reduction ratio, liberation, specific surface energy, and specific surface area. The results showed that the fracture of low-grade hematite ore in HPGR was an interactive dynamic process in which the interaction between coarse particles of gangue minerals and fine particles of valuable minerals was alternately continuous with increased compactness and compacting strength of materials. Within a range of 2.8–4.4 N/mm^2, valuable minerals were crushed after preferentially absorbing energy, whereas gangue minerals were not completely crushed and only acted as an energy transfer medium. Within a range of 4.4–5.2 N/mm^2, gangue minerals were adequately crushed after absorbing the remaining energy, whereas preferentially crushed valuable minerals acted as an energy transfer medium. Within a range of 5.2–6.0 N/mm^2 range, the low-grade hematite ore was not further comminuted because of the "size effect" on the strength of materials, and the comminution effect of materials became stable.

Characteristics and Mechanism of Modified Triethanolamine as Cement Grinding Aids

Effects of modified triethanolamine as cement grinding aids on particles characteristics and mechanical property of cement were studied, and its reaction mechanism was analyzed by IR, Zeta potential, SEM, XRD and TG-DTA. The results show that the content of 3-32 μm particles for cement with 0.015% modified triethanolamine（M-TEA） is increased by 12.4%, and the compressive strengths of cement with 0.03% M-TEA are increased by 5.5 and 8.2 MPa at 3 and 28 days, respectively. And both the grinding and enhancement effects of M-TEA on cement are better than triethanolamine. The mechanism analysis shows that M-TEA not only has the amino and hydroxyl groups of TEA, but also has the ester, carbonyl, carboxyl groups which easily combine with metal ions of cement minerals, resulting in that M-TEA can promote surface adsorption and shield the unsaturated charges in the surface and crack section of particles, thus particles reunion is prevented and grinding efficiency is improved. Enhancement of M-TEA on cement mainly lies in that it can promote or induce hydration reaction of cement mineral with gypsum and water, which accelerates formation of hydration products, and then improves the structure and morphology of cement hydration products, thus the uniformity and compactness of product structure is increased.

Unsteady-State Grinding Technology (I) Theoretical Generalization and Research on Grinding Mechanism

In conventional grinding theory, it is obvious that there must be a very high hardness difference between grains of the grinding wheel and workpieces. The best grinding wheels are those giving the lowest "natural limiting surface roughness" while cutting at appreciable plunge velocities. With the development of new materials and new machining processes, conventional theories of grinding techniques are no longer suitable to explain many phenomena in the course of grinding procedures. In dealing with precision or ultra-precision grinding processes of advanced ceramics, many results of experiments and practical production have shown that grinding with super hard materials wheels is not the only method to machine advanced ceramics. This paper is intended to propose a new grinding theory named as unsteady-state grinding technique evolved from some phenomena that can not be explained by conventional grinding theory. Unsteady-state grinding technique means the technique which can make the surface roughness of the materials, especially hard and brittle, be up to the standard of ultra-precision machining by utilizing common wheels characteristic of inferior self-sharpening and wear-resistance. In the process of machining, the common wheel need to be redressed about 3～5 times and the time between two redressings is about 3～5 minutes. As a validation of the new grinding technology, experimental work was performed to prove the existence of the unsteady state in the process of ultra-precision grinding with common abrasive wheel-pink fused alumina wheel. From the results of the observation of the wheel topography, the whole grinding process in unsteady state was separated into three stages namely cutting by grains peaks, micro-cutting by micro edges of the broken grains and rubbing without material removal, which is different from conventional grinding theory. For the difference of hardness between grinding wheel and workpiece material is not so apparent, some people have doubts about whether the cutting especially micro-cutting actions exist in the process of unsteady state grinding. By utilizing the common abrasive wheel newly redressed to grind the finished surface of silicon nitride glut and comparing the finished surface with the damaged surface in SEM pattern and surface roughness, the existence of cutting and micro- cutting actions in the unsteady state grinding process was confirmed.

THE SELF-GRINDING MECHANISM AND AFFECTING FACTORS OF BULK MATERIAL IN FLUID MOTION

The fluidity and classification of bulk material (loose body) were introduced, the self-grinding mechanism and the affecting factors of bulk materials in various forms of phase, state and motion were investigated. A rotational-flow-state centrifugal autogenous grinder was developed on the basis of applying self-grinding mechanism of bulk material,the result tested by the autogenous grinder was compared with that tested by 4R Raymond mills, and fine particles with extremely high specific area were obtained. The feasibility of the developed new-type autogenous grinder in the view of fluid motion of bulk material was proved.

Hydriding/dehydriding properties of Mg-Ni-based ternary alloys synthesized by mechanical grinding

The Mg-Ni-based ternary alloys Mg2-xTixNi(x=0,0.2,0.4)and Mg2Ni1-xZrx(x=0,0.2,0.4)were successfully synthesized by mechanical grinding.The phases in the alloys and the hydriding/dehydriding properties of the alloys were investigated.Mg2Ni and Mg are the main hydrogen absorption phases in the alloys by XRD analysis.Hydriding kinetics curves of the alloys indicate that the hydrogen absorption rate increases after partial substitution of Ti for Mg and Zr for Ni.According to the measurement of pressure-concentration-isotherms and Van't Hoff equation,the relationship between ln p(H2)and 1 000/T was established.It is found that while increasing the content of correspondingly substituted elements at the same temperature,the equilibrium pressure of dehydriding increases,the enthalpy change and the stability of the alloy hydride decrease.

MECHANICAL-ELECTRIC COUPLING DYNAMICAL CHARACTERISTICS OF AN ULTRA-HIGH SPEED GRINDING MOTORIZED SPINDLE SYSTEM

On the basis of the traditional mechanical model of a grinding wheel rotor and the mechanical-electric coupling model with ideal sinusoidal supply, taking high-frequency converting current of inverter power switches into further consideration, a modified mechanical-electric coupling model is created. The created model consists of an inverter, a motorized spindle, a grinding wheel and grinding loads. Some typical non-stationary processes of the grinding system with two different supplies, including the starting, the speed rising and the break in grinding loads, are compared by making use of the created model. One supply is an ideal sinusoidal voltage source, the other is an inverter. The theoretical analysis of the high-order harmonic is also compared with the experimental result. The material strategy of suppressing high-order harmonic mechanical-electric coupling vibration by optimizing inverter operating parameters is proposed.

Orientation variation along growth direction of millimeter free-standing CVD diamond thinned by mechanical grinding

A free-standing diamond film with millimeter thickness prepared by DC arc plasma jet was thinned successively by mechanical grinding. The orientation and quality of the diamond films with different thicknesses were characterized by X-ray diffraction and Raman spectroscopy, respectively. The results show a random grain-orientatinn distribution during the initial growth stage. As the film thickness increases, the preferred orientation of the diamond film changes from （111） to （220）, due to the competitive growth mechanism. Twinning generated during the nucleation stage appears to stabilize the preferential growth along the 〈110〉 direction. The interplanar spacing of the （220） plane is enlarged as the film thickness increases, which is caused by the increase of non-diamond-phase carbon and impurities under the cyclic gas. In addition, the quality of the diamond film is barely degraded during the growth process. Furthermore, the peak shift demonstrates a significant inhomogeneity of stress along the film growth direction, which results from competitive growth.

Mechanical Property of Low Chromium Semi-Steel Grinding Ball Prepared by Cross Rolling

The preparing method,rolling technology and mechanical properties of low chromium semi-steel grinding ball by cross rolling were studied.The results show that when the low chromium semi-steel bar is forged from55mm to50mm,cross-rolled into grinding ball at 1 000-1 050℃,air cooled and tempered at 550℃for 2h,the best mechanical properties,especially the abrasive resistance under the action of hard abrasive,can be obtained.

XRD Characterization of Crystallinity of Human Tooth Enamel under Influence of Mechanical Grinding

Crystallinity refers to the degree of structural order in a solid and has a big influence on hardness, density, transparency and diffusion. Even within materials that are crystalline completely, the degree of structural perfection can vary, reflecting size and elastic strain of many independent crystalline regions (grains or crystallites) of which these materials are composed. In this work it was attempted to reduce the crystallinity of human enamel using a technique of mechanical grinding (MG) with an ultra-compact FRITSCH Mini-Mill PULVERISETTE 23 machine. Variation in the crystallinity through the MG was monitored by X-ray diffraction (XRD) by broadening of the diffraction peak and examined using the Williamson-Hall plot method. Crystallites in human enamel are regularly arranged and oriented (in the [001] direction) perpendicularly to the interface of enameldentin junction. The results showed an anisotropic feature in crystallinity. Reduction of the crystallinity along the a-axis is due to the crystal strain rather than to the refinement of crystal, and vice versa along the c-axis. After 230 h of the MG, the length of crystallites decreased from 100 nm to 30 nm and width from 40 nm to 37 nm approximately.

Influence of Mechanical Grinding on the Interface Characteristics of Rice/Wheat Straws

The mechanical grinding method was used to make rice and wheat straw flakes and the properties of the interface of straws before and after grinding were evaluated. The particle boards were prepared using two kinds of straw flakes, respectively and their physical and mechanical properties were investigated. The results showed that the rice straw was easier to be broken when compared with wheat straw and the inner surface of cells in grinded straws was exposed remarkably. The characteristic peaks of lignin and cellulose on the surface of wheat straw were more significant than rice straw. The free-radical concentrations of straws were increased dramatically after being grinded with heating in the range from I00 ~C to 200 ~C. The surface free energy of straws was also improved after being grinded and the value in wheat straw was higher than that of rice straw, which implies that wheat straw was easier to be bonded than rice straw. The physical and mechanical properties of two kinds of straw particle boards could achieve the requirements of Chinese National Standards of GB 4897.3-2003, while wheat straw particle boards had better properties than those made from rice straws.

The Effect of the Grinding Time on the Mechanical Activation of MnO2 Ore and Tea Plant Waste Carbonization Product

In this study, pyrolusiteore （MnO2） was subjected to mechanical milling with a high-energy mill with carbonized tea plant wastes and the effect of grinding time on the crystal structure of the material was investigated. The ratio of Mn/Fe was 8/1, the ratio of C/（MnO2 ＋ Fe3O4） was 2 and the ratio of ball to ore was 10/1. The samples were mechanically ground at 10, 15, 20, 30, 60, 90 and 120 hours. In the processes performed on the attritor, the rotation speed of the mill shaft was determined to be 350 rpm. The results were characterized by TG-DTA, SEM and XRD analyzes. As a result of the experimental studies, it was observed that the samples subjected to mechanical grinding for 120 hours were gradually reduced due to the increasing grinding time at all the diffraction peaks when the XRD peaks were compared with the grinding times. In the thermogravimetric analysis, the sample milled for 120 hours, 50% weight loss was observed at 470 ℃, weight loss of up to 56% was observed at progressive temperatures.

Particle Removal Mechanism of High Volume Fraction SiCp/Al Composites by Single Diamond Grit Tool

Particle removal mechanism was presented during machining particle SiC/Al composites with diamond grinding tool. The relevant removal modes and their mechanisms were discussed considering the impact and squeezing effect of diamond grit on the SiC particle. The experimental results show that the aluminum matrix has larger plastic deformation, so the aluminum mixed with the surplus SiC particles is cut from the surface. The SiC particles can be removed in multiple ways, such as broken/fractured, micro cracks, shearing and pulled out, etc. More particles removed by shearing, and less particles removed by fractured during material removal progress can produce a better machined surface.

Precision Grinding of Reaction Bonded Silicon Carbide Using Coarse Grain Size Diamond Wheels

Reaction bonded SiC（RBSiC） is attractive for optical application because of its favorable properties and low fabrication cost. However, the difficultness and cost involved in RBSiC grinding limit its application. The investigation on high efficient and low-cost machining with good grinding quality is desired. Generally, high efficient machining for RBSiC is realized by using coarse grain size grinding wheels, but serious grinding damage is inevitable. In this paper, monolayer nickel electroplated coarse grain size diamond grinding wheels with grain sizes of 46 μm, 91 μm, and 151 μm were applied to the grinding of RBSiC. An electrolytic in-process dressing（ELID） assisted conditioning technique was first developed by using cup shape copper bonded conditioning wheels with grain sizes of 15 μm and 91 μm to generate the conditioned coarse grain size wheels with minimized wheel run-out error within 2 μm, constant wheel peripheral envelop as well as top-flattened diamond grains. Then, the grinding experiments on RBSiC were carried out to investigate the grinding performance and material removal mechanism. The experimental results indicate that the developed conditioning technique is applicable and feasible to condition the coarse grain size diamond wheels under optimal conditioning parameters, and the material removal mechanism involved in RBSiC grinding is the combination of brittle fracture and ductile deformation to generate smooth ground surface. This research is significant for the high efficient and low-cost precision grinding of RBSiC with good ground surface quality.

Formation mechanism and wear behavior of gradient nanostructured Inconel 625 alloy

The formation mechanism and wear behavior of a gradient nanostructured(GNS) Inconel 625 alloy were investigated using SEM, TEM and ball-on-disc sliding wear tester. The results show that surface mechanical grinding treatment(SMGT) induced an approximately 800 μm-deep gradient microstructure, consisting of surface nano-grained,nano-laminated, nano-twined, and severely deformed layers, which resulted in a reduced gradient in micro-hardness from 6.95 GPa(topmost surface) to 2.77 GPa(coarse-grained matrix). The nano-grained layer resulted from the formation of high-density nano-twins and subsequent interaction between nano-twins and dislocations. The width and depth of the wear scar, wear loss volume, and wear rate of the SMGT-treated sample were smaller than those of untreated coarse-grained sample. Moreover, the wear mechanisms for both samples were mainly abrasive wear and adhesive wear, accompanied with mild oxidation wear. The notable wear resistance enhancement of the GNS Inconel 625 alloy was attributed to the high micro-hardness, high residual compressive stress, and high strain capacity of the GNS surface layer.

Strengthening pelletization of manganese ore fines containing high combined water by high pressure roll grinding and optimized temperature elevation system

Pelletization is one of useful processes for the agglomeration of iron ore or concentrates. However, manganese ore fines are mainly agglomerated by sintering due to its high combined water which adversely affects the roasting performance of pellets. In this work, high pressure roll grinding(HPRG) process and optimization of temperature elevation system were investigated to improve the strength of fired manganese ore pellets. It is shown that the manganese ore possesses good ballability after being pretreated by HPRG twice, and good green balls were produced under the conditions of blending 2.0% bentonite in the feed, balling for 7 min at 16.00% moisture. High quality roasted pellets with the compressive strength of 2711 N per pellet were manufactured through preheating at 1050 °C for 10 min and firing at 1335 °C for 15 min by controlling the cracks formation. The fired manganese pellets keep the strength by the solid interconnection of recrystallized pyrolusite grains and the binding of manganite liquid phase which filled the pores and clearance among minerals. The product pellets contain high Mn grade and low impurities, and can be used to smelt ferromanganese, which provides a possible way to use imported manganese ore fines containing high combined water to produce high value ferromanganese.

Discussion on the Application of LS-DYNA in Superfine Grinding of Wheat Bran

Superfine grinding, involving the fragmentation mechanism of wheat bran cell tissue, is being employed by milling industry. In order to determine the effect of wheat bran cell tissue on the fragmentation mechanism when using superfine grinding,a technical scheme of the nonlinear finite element numerical simulation method based on LS-DYNA is proposed in this paper.The physiological characteristics of wheat bran structural layers including outer pericarp, intermediate layer and aleurone layer are examined first, and then the mechanical properties of wheat bran structural layers and their effects on the super fine grinding process are analyzed. Secondly, the explicit time integration algorithm of LS-DYNA is introduced, and the application feasibility of LS-DYNA in the analysis of wheat bran superfine grinding mechanism is discussed. Finally, the specific application of LS-DYNA in the determination of grinding form and load, the selection and design of the grinding media and the selection of grinding temperature are discussed in detail in the process of superfine grinding for wheat bran cell tissue. The above research provides a theoretical basis for selecting and developing the equipment and technology suitable for wheat bran superfine grinding, and lays a theoretical foundation for enhancing the quality and efficiency of wheat bran superfine grinding.

High Efficiency Axial Deep Creep-Feed Grinding Machining Technology of Engineering Ceramics Materials

Axial deep creep-feed grinding machining technology is a high efficiency process method of engineering ceramics materials, which is an original method to process the cylindrical ceramics materials or hole along its axis. The analysis of axial force and edge fracture proved the cutting thickness and feed rate could be more than 5-10 mm and 200 mm/min respectively in once process, and realized high efficiency, low-cost process of engineering ceramics materials. Compared with high speed-deep grinding machining, this method is also a high efficiency machining technology of engineering ceramics materials as well as with low cost. In addition, removal mechanism analyses showed that both median/radial cracks and lateral cracks appeared in the part to be removed, and the processed part is seldom destroyed, only by adjusting the axial force to control the length of transverse cracks.